connector

Abstract

A splice connector for connecting architectural panels together, the connector comprising two wall portions, and at least one joining portion connecting the two wall portions, wherein the two wall portions comprise a compressible material configured to exert an outward force on at least two interior surfaces of an architectural panel when inserted into an interior space defined by the panel.

Description

BACKGROUND

[0001] The present invention relates to a connector, and in particular a splice connector for connecting architectural panels together. The present invention also relates to an architectural assembly comprising a connector, a blank configured to form the connector, and manufacturing methods of a connector.

[0002] Connectors for connecting architectural panels together are well known. Such a connector is typically known as a splice connector. These connectors may be used to connect various types of architectural panels together, including but not limited to ceiling panels (which may be baffle ceiling panels) and wall panels.

[0003] Known connectors are typically placed in an interior space defined by the panel, in order to allow the joining together of two panels which abut each other. In such arrangements, the connector is made so as to have an external dimension which is smaller than the corresponding interior dimension of the panel, so that the splice connector can be placed in (i.e. fits into) the interior space. However, the sizing of the connector may mean that there is some room for movement at the join between two adjacent panels, which may mean that the panels are not securely joined together, may affect the alignment of the panels, and may result in a visible gap between adjacent panels.

[0004] It is an aim of the present invention to at least partially address the problems noted above.SUMMARY OF THE INVENTION

[0005] According to a first aspect, there is provided a splice connector for connecting architectural panels together, the connector comprising two wall portions and at least one joining portion connecting the two wall portions wherein the two wall portions comprise a compressible material configured to exert an outward force on at least two interior surfaces of an architectural panel when positioned in an interior space defined by the panel. This may provide a secure fit and accurate alignment of panels connected by the connector. This may also prevent visible gaps from forming between panels, which may in turn give the appearance of a single continuous panel.

[0006] Optionally, the at least one joining portion comprises said compressible material.

[0007] Optionally, at least one joining portion is configured to exert an outward force on an interior surface of the panel when positioned in an interior space defined by the panel.

[0008] Optionally, the connector is formed of said compressible material.

[0009] Optionally, the connector is formed of a single piece of folded material. This may provide ease of manufacture and reduce manufacturing cost.

[0010] Optionally, the compressible material is felt.

[0011] Optionally, the compressible material is rubber or a polymeric material.

[0012] Optionally, the connector further comprises two joining portions connecting the two wall portions at different positions along the wall portions.

[0013] Optionally, the wall portions and joining portions form a rectangular cross-section. This may provide improved rigidity of the connector.

[0014] Optionally, the connector further comprises a cut-out portion configured to engage with an end surface of an architectural panel. This may provide accurate positioning of the panel relative to the connector.

[0015] Optionally, the cut-out portion is positioned on the joining portion.

[0016] Optionally, the wall portions and the joining portion extend in a longitudinal direction, and the cut-out portion is located at the mid-point of the connector in the longitudinal direction.

[0017] Optionally, the connector further comprises a plurality of said cut-out portions.

[0018] Optionally, a first cut-out portion and a second cut-out portion are respectively positioned where the joining portion meets the respective two wall portions. This may allow the connector to be inserted in more than one orientation.

[0019] Optionally, each cut-out portion defines a respective engagement surface configured to come into contact with a longitudinal end surface of a panel, wherein the engagement surfaces face in opposite longitudinal directions. This may allow the connector to be inserted in more than one orientation.

[0020] Optionally, the engagement surfaces are located at the same longitudinal position along the connector. This may allow the connector to be located at the same position relative to the panel for more than one insertion orientation.

[0021] According to a second aspect, there is provided a blank of compressible material configured to be folded to form the connector as described above.

[0022] According to a third aspect, there is provided an architectural assembly comprising the splice connector as described above, and at least one architectural panel. This may provide a secure fit and accurate alignment between the connector and the panel.

[0023] Optionally, the splice connector is formed of a material which is more compressible than the material of the architectural panel.

[0024] Optionally, the panel is formed of a metallic material.

[0025] Optionally, the panel has two panel wall portions and a panel joining portion defining an interior space, the panel joining portion having a first length between the panel wall portions in the interior space, the external surface of the joining portion of the connector between the two wall portions has a second length, and the second length is greater than the first length when the connector is not disposed in the interior space.

[0026] Optionally, the panel is a ceiling panel, preferably a baffle ceiling panel.

[0027] Optionally, the architectural assembly comprises a plurality of said panels, connected by said connector. This may provide a secure fit and accurate alignment between the two panels.

[0028] According to a fourth aspect, there is provided a method of manufacturing a splice connector for connecting architectural panels together, the method comprising providing a blank of compressible material, and folding the blank so as to form two wall portions and at least one joining portion spanning the two wall portions, such that the wall portions are configured to exert an outward force on at least two interior surfaces of an architectural panel when positioned in an interior space defined by the panel.BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will now be described, by way of non-limitative example only, with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of a connector according to the present invention; Figure 2 shows an end view of the connector of figure 1; Figure 3 shows a top view of the connector of figure 1; Figure 4 shows a panel with which the connector of figures 1-3 can be used; Figure 5 shows an architectural assembly comprising the connector of figures 1-3 and the panel of figure 4; Figure 6 shows a close-up of the region labelled "A" in figure 5; Figure 7 shows a perspective view of a blank configured to form the connector of figures 1-3; and Figure 8 shows a top view of the blank of figure 7. DETAILED DESCRIPTION

[0030] An example connector of the present invention is shown in figures 1-3. The connector 10 is a splice connector for connecting (i.e. joining, or splicing) architectural panels together (i.e. to each other). In other words, the connector is configured to join a first architectural panel to a second architectural panel. The connector is configured to connect the panels end-to-end. In other words, the panels extend in a longitudinal direction, and the connector joins longitudinal ends of the panels.

[0031] The connector comprises a first wall portion 11a and a second wall portion 11b. The connector further comprises at least one joining portion, which connects (i.e. joins) the wall portions together. In the arrangement of figures 1-3, the connector includes a first joining portion 12a and a second joining portion 12b. The joining portion 12a connects (i.e. joins) the first wall portion 11a to the second wall portion 11b. That is, the first joining portion 12a spans between the first wall portion 11a and the second wall portion 11b. Likewise, the second joining portion 12b connects (i.e. joins) the first wall portion 11a to the second wall portion 11b. That is, the second joining portion 12b spans between the first wall portion 11a and the second wall portion 11b. The first wall portion 11a, the second wall portion 11b, the first joining portion 12a, and the second joining portion 12b define a space (or cavity) therebetween. The first wall portion 11a, the second wall portion 11b, the first joining portion 12a, the second joining portion 12b (and thus the connector 10 itself) all extend in a longitudinal direction, depicted by arrow L in figure 1.

[0032] It will be understood that the first joining portion 12a and the second joining portion 12b are located at (and thus connect the two wall portions together at) different positions along the wall portions. In the example shown in figures 1 and 2, the joining portions 12a, 12b join the wall portions 11a, 11b at opposite ends thereof. The first wall portion 11a, the second wall portion 11b, the first joining portion 12a and the second joining portion 12b thus form a rectangular cross-section (taken parallel to a plane that is perpendicular to the longitudinal direction L of the connector) with a hollow interior (i.e. an empty space or cavity is defined between the four portions).

[0033] Although the arrangement described above and shown in figures 1-3 includes a first joining portion 12a and a second joining portion 12b, it will be understood that arrangements are possible in which either of the first joining portion 12a and second joining portion 12b is omitted (i.e. only a single joining portion is present).

[0034] The first wall portion 11a and the second wall portion 11b comprise a compressible material. The compressible material is configured to exert an outward force on at least two interior surfaces of an architectural panel when inserted into an interior space by the panel. That is, the compressibility of the material allows the material to be compressed to some extent when inserted into a panel (i.e. an interior space defined by the panel), and thus to exert an outward force on the interior surfaces of the panel once located inside the interior space. In order to allow such an outward force to be exerted, one or more dimensions of the connector may be be slightly bigger than the corresponding dimensions of the panel into which it is to be inserted. This outward force may provide a more secure fit between the connector and the panel, and may allow improved alignment between two panels which are joined by the connector (because there is no room for relative movement therebetween)

[0035] One or both of joining portions 12a and 12b may also comprise a compressible material, and may thus also exert an outward force on an interior surface of the panel when inserted into an interior space defined by the panel, in a similar manner to the wall portions 11a, 11b.

[0036] In some arrangements, the connector may be formed of the compressible material. That is, the connector may be substantially exclusively formed of the compressible material, and not include any other materials. For example, the connector may be formed of a single piece of folded material. However, it will be understood that in some arrangements, other materials (which may be compressible or non-compressible) may be present. Merely as an example, the connector may have an inner "liner" made of a non-compressible material, such as a metallic sheet material.

[0037] The compressible material may be felt. Any type of felt, including natural (e.g. wool) felt or synthetic felt, may be used. The compressible material may also be rubber, or a polymeric material. For example, a polymeric foam may be used. Examples of suitable polymeric foams include polyurethane (PU) foams, polystyrene (PS) foams, poly(vinyl chloride) (PVC) foams, polyethylene (PE) foams, polypropylene (PP) foams, nitrile rubber (NBR) foams, polyisocyanurate (PIR) foams, poly(ethylene-vinyl acetate) (PEVA) foams, or any combination thereof. It will be understood that other suitable compressible materials may be used.

[0038] As shown in figures 1-3, the connector may further include one or more cut-out portions configured to engage with an end surface of an architectural panel. The cut-out portions may be provided on an external surface of the connector. For example, in the arrangement shown in figures 1-3, two cut-out portions are provided (i.e. a first cut-out portion 13a and a second cut-out portion 13b).

[0039] In the arrangement shown in figures 1 and 3, the cut-out portions are positioned on the second joining portion 12b (and in particular on the external surface thereof). However, other arrangements are possible in which the cut-out portions are positioned otherwise so as to engage with an end surface of an architectural panel.

[0040] The cut-out portion or portions may be configured so as to come into contact with an end surface of the panel, which may in turn prevent the panel from moving further relative to the connector. In particular, each cut-out portion may define an engagement surface which is configured to come into contact with a longitudinal end surface of the panel when the connector is positioned in the interior space of the panel. Thus, the cut-out portions may prevent the connector from being pushed too far into the interior space of a panel, thus preventing a situation in which a second panel cannot be connected to the first panel via the connector. The function of the cut-out portion will be further described later in the description of an assembly including the connector and a panel.

[0041] It will be understood that the term "cut-out portion" encompasses a a complete cut through the material of the connector (i.e. a through hole or complete cut through), as well as a partial cut through the material of the connector (i.e. an indentation in the surface of the connector, or a partial cut through).

[0042] In the arrangement shown in figures 1 and 3, the two cut-out portions are respectively positioned where the joining portion 12b on which they are located meets the respective two wall portions (i.e. at opposite ends of the joining portion 12b in the direction in which the joining portion extends between the two wall portions). That is, a first cut-out portion 13a is located where the joining portion 12b meets the first wall portion 11a, and a second cut-out portion 13b is located where joining portion 12b meets the second wall portion 11b.

[0043] Further, in the arrangement shown in figure 1 and 3, the cut-out portions 13a and 13b are located at the longitudinal mid-point of the joining portion 12b (i.e. at the mid-point of the connector in the longitudinal direction).

[0044] Figure 4 depicts an example panel with which the connector of the invention can be used. The panel comprises a first panel wall portion 21a, a second panel wall portion 21b, and a panel joining portion 22. The two panel wall portions and the panel joining portion define an interior space therebetween.

[0045] The panel further comprises two hook portions (or flanges), namely a first hook portion 23a and a second hook portion 23b, which are respectively at the opposite end of wall portions 21a and 21b to joining portion 22 (i.e. at the open end of the interior space). As will be described in more detail below, the two hook portions may interact with the cut-out portions of the connector, in order to retain the correct relative positioning of the panels and the connector.

[0046] The first panel wall portion 21a, the second panel wall portion 21b, and the panel joining portion 22 (and thus the panel 20 itself) all extend in a longitudinal direction, depicted by arrow L in figure 4. It will be understood that when the connector is inserted into the panel, the longitudinal direction of the connector and the longitudinal direction of the panel are parallel to each other.

[0047] Figure 5 shows an architectural assembly comprising the connector 10 shown in figures 1-3, and the panel 20 shown in figure 4. In the assembly of figure 5, the connector 10 has been inserted into (i.e. is located in) the interior space of the panel 20. In order to allow the wall portions of the connector to exert an outward force on the interior of the wall portions of the panel 20, the connector comprises (and in some arrangements is formed of) a material which is more compressible than the material of the architectural panel. For example, for a panel made of a metallic sheet material (which metal is of substantially incompressible), a felt, rubber or polymeric foam material, as described above, may be used to form the connector.

[0048] It will be appreciated that a further panel may be added to the assembly of figure 5 at the opposite end of the connector 10 to panel 20 (i.e. the left-hand side of figure 5). Thus, two panels may be joined together by connector 10.

[0049] In order to allow the wall portions of the connector to exert an outward force on the interior of the wall portions of the panel 20, the panel joining portion 22 may have a first length (marked "a" in figure 4) between the panel wall portions in the interior space, and the external dimension of the joining portion 11 of the connector 10 between the two wall portions 11a, 11b of the connector (marked "b" in figures 1 and 2) may be a second length. If the second length (i.e. dimension "b") is chosen to be greater than the first length (i.e. dimension "a") when the connector is not disposed in the interior space, the wall portions of the connector may be compressed when the connector is inserted into the interior space, by virtue of the relevant external dimension of the connector (in the uncompressed state) being larger than the corresponding internal dimension of the panel. This may in turn provide a secure fit, and improved alignment between the panel and subsequent panels which are added to the assembly.

[0050] Further, the hook portions may dig in to the compressible material of the connector when the connector is disposed in the internal space of the panel. Thus, the second joining portion 12b of the panel may exert an outward force on the panel (and in particular on the hook portions 23a, 23b thereof) when positioned in the interior space of the panel. It will be understood that the resultant (downward) force exerted by the hook portion on the connector may also result in an outward force being exerted by the first joining portion 12a on the panel (and in particular on the panel joining portion 22).

[0051] Figure 6 shows a close-up of the region marked A in figure 5. In particular, figure 6 depicts the interaction between the hook portion 23b of the panel 20 and the cut-out portion 13b of the connector 10. When the connector is inserted into the interior space of panel 20, the hook portion slides along the upper surface of joining portion 12b of panel 10 (which it can do because of the compressibility of the joining portion), until it meets the cut-out portion. The hook portion (or the free end thereof) then moves into the space defined by the cut-out portion 13b. The end surface of the hook portion then abuts one of the edges of the cut-out portion, meaning that the connector cannot slide any further. This prevents, for example, the connector being pushed so far into the interior surface of the panel such that it is flush with the end of the panel, i.e. does not protrude beyond the end of the panel. This would prevent a second panel from being joined to the assembly (because there would be no part of the connector protruding from the first panel to connect to the second panel). Thus, the cut-out portion or portions may provide correct positioning of the connector relative to the panel such that a second panel can be attached to the assembly.

[0052] Where two cut-out portions are provided, the cut-out portions may define engagement surfaces which face opposite longitudinal directions (i.e. the two directions shown by the arrowheads marked L in figure 1). For example, in the arrangement shown in figures 1 and 3), the first cut-out portion 13a defines a first engagement surface 13a1, and the second cut-out portion 13b defines a second engagement surface 13b1. The engagement surfaces are planar surfaces which extend perpendicular to the longitudinal direction. Furthermore, the first engagement a first engagement surface 13a1 and the second engagement surface 13b1 face in opposite longitudinal directions (i.e. each towards one of the two arrowheads of the line labelled L in figure 1). This may allow the connector to be inserted into the panel either longitudinal end first, because one of the hook portions can interact with one of the cut-out portions, regardless of which end of the connector is inserted into the panel.

[0053] Further, if two cut-out portions are arranged such that their engagement surfaces face in opposite directions but are located at the same longitudinal position along the connector (e.g. in a rotationally symmetrical arrangement as shown in figures 1 and 3, for example), the connector not only can be inserted into the panel either end first (i.e. at orientations 180 degrees apart about the same axis of rotation as the axis of rotational symmetry), but will also be stopped from moving further into the panel at the same position (i.e. leave the same amount of connector protruding from the interior surface of the panel) regardless of which end of the connector is inserted into the panel.

[0054] Figures 7 and 8 depict a blank 30 which is configured to form the connector shown in figures 1-3. The blank 30 of figures 7 and 8 can be folded so as to form connector 10. As explained above, the connector may be formed from a single piece of material. Thus, a blank formed of a single piece of material may be provided, which is then folded so as to form the connector.

[0055] In arrangements where the connector has a rectangular box section, the two ends of the blank may be configured to be joined together, by, for example, a set of interlocking teeth as shown in figures 7 and 8. The blank may also include score lines which allow the blank to be folded.

[0056] The connector as described above may be manufactured by any suitable method. However, in one arrangement, the method may include providing a blank of compressible material (such as that shown in figures 7 and 8), and folding the compressible material so as to form the connector. That is, the blank may be folded so as to form two wall portions and at least one joining portion spanning the two wall portions, such that the wall portions are configured to exert an outward force on at least two interior surfaces of an architectural panel when inserted into an interior space defined by the panel.

[0057] Although a particular arrangement of connector is described above, it will be appreciated that other arrangements can be provided. For example, arrangements are possible in which the joining portions are not positioned at the ends of the wall portions. For example, the joining portions may be provided at intermediate positions along the wall portions rather than at the ends thereof (which may result in a cross section with a ladder-like shape rather than a closed rectangle). In other arrangements, only a single joining portion may be present. For example, this may provide a U-shaped cross-section rather than a rectangular cross-section.

[0058] Likewise, arrangements are possible in which a single cut-out portion is be provided, rather than the two cut-out portions depicted in figures 1-3. For example, a single cut-out portion (e.g. a slot extending between the two wall portions) may define two engagement surfaces which face opposite longitudinal directions, rather than two engagement surfaces being provided by two separate cut-out portions. Alternatively, the cut-out portions may be omitted altogether.

[0059] Further, although in the arrangements described above, the wall portions and joining portion(s) define a space or cavity therebetween, arrangements are possible in which no cavity is present (i.e. the wall portions and joining portions are all integrally formed with no space therebetween, forming a solid block comprising the compressible material configured to exert the outward force described above). In such arrangements, any of the above-described arrangements of cut-out portion or portions may be provided in an outer surface of the connector.

[0060] Although a particular arrangement of panel is described above, it will be appreciated that other arrangements can be provided. The panel may be a ceiling panel, such as a baffle ceiling panel. The panel may also be a wall panel, or any other type of architectural panel.

[0061] It should be understood by those skilled in the art that while the present invention has been described with reference to exemplary embodiments, it is not limited to the disclosed exemplary embodiments. Various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. Features from any example or embodiment of the present disclosure can be combined with features from any other example or embodiment of the present disclosure.

Claims

1. A splice connector for connecting architectural panels together, the connector comprising: two wall portions; and at least one joining portion connecting the two wall portions; wherein the two wall portions comprise a compressible material configured to exert an outward force on at least two interior surfaces of an architectural panel when positioned in an interior space defined by the panel.

2. The connector of claim 1, wherein the at least one joining portion comprises said compressible material.

3. The connector of claim 2, wherein at least one joining portion is configured to exert an outward force on an interior surface of the panel when positioned in an interior space defined by the panel.

4. The connector of claim 1, 2 or 3, wherein the connector is formed of said compressible material; and / or wherein the connector is formed of a single piece of folded material.

5. The connector of any preceding claim, wherein the compressible material is felt or rubber or a polymeric material.

6. The connector of any preceding claim, comprising two joining portions connecting the two wall portions at different positions along the wall portions; optionally wherein the wall portions and joining portions form a rectangular cross-section.

7. The connector of any preceding claim, further comprising a cut-out portion configured to engage with an end surface of an architectural panel; optionally wherein the cut-out portion is positioned on the joining portion.

8. The connector of claim 7, wherein the wall portions and the joining portion extend in a longitudinal direction, and the cut-out portion is located at the mid-point of the connector in the longitudinal direction.

9. The connector of claim 7 or 8, further comprising a plurality of said cut-out portions; optionally wherein a first cut-out portion and a second cut-out portion are respectively positioned where the joining portion meets the respective two wall portions.

10. The connector of claim 9, wherein each cut-out portion defines a respective engagement surface configured to come into contact with a longitudinal end surface of a panel, wherein the engagement surfaces face in opposite longitudinal directions; optionally wherein the engagement surfaces are located at the same longitudinal position along the connector.

11. A blank of compressible material configured to be folded to form the connector of any preceding claim.

12. An architectural assembly comprising the splice connector of any preceding claim, and at least one architectural panel; optionally wherein the splice connector is formed of a material which is more compressible than the material of the architectural panel; and / or wherein the panel is formed of a metallic material.

13. The architectural assembly of claim 12, wherein: the panel has two panel wall portions and a panel joining portion defining an interior space, the panel joining portion having a first length between the panel wall portions in the interior space, the external surface of the joining portion of the connector between the two wall portions has a second length; and the second length is greater than the first length when the connector is not disposed in the interior space.

14. The architectural assembly of claim 12 or 13, wherein the panel is a ceiling panel, preferably a baffle ceiling panel.

15. The architectural assembly of any of claims 12-14, comprising a plurality of said panels, connected by said connector.

16. A method of manufacturing a splice connector for connecting architectural panels together, the method comprising: providing a blank of compressible material; folding the blank so as to form two wall portions and at least one joining portion spanning the two wall portions, such that the wall portions are configured to exert an outward force on at least two interior surfaces of an architectural panel when positioned in an interior space defined by the panel.

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